Tool assembly for manufacturing parts and a method of producing a tool assembly

Abstract

A tool assembly and a method for manufacturing and sealing a tool assembly for manufacturing an article includes building a tool assembly using additive manufacturing or 3D printing processes.

What is claimed is: 
     
         1 . A method comprising:
 receiving a tool assembly including a plurality of layers defining at least one part-cavity and plurality of cooling channels;   pouring sealant into the plurality of cooling channels;   pressurizing the sealant to a pressure for a pressurization period; and   applying a centrifugal force to the tool assembly to remove excess sealant from the tool assembly, wherein the sealant extends between the plurality of layers.   
     
     
         2 . The method as recited in  claim 1 , further comprising:
 heating the tool assembly in an oven at approximately seventy degrees Celsius for approximately four hours.   
     
     
         3 . The method as recited in  claim 2 , further comprising:
 pouring the sealant into the tool assembly while the tool assembly is at or near seventy degrees Celsius.   
     
     
         4 . The method as recited in  claim 3 , wherein the sealant is pressurized to a pressure ranging from approximately sixty pounds per square inch to approximately one hundred pounds per square inch. 
     
     
         5 . The method as recited in  claim 4 , wherein the pressurization period comprises at least thirty seconds. 
     
     
         6 . The method as recited in  claim 4 , wherein the pressurization period comprises at least sixty seconds. 
     
     
         7 . The method as recited in  claim 3 , wherein the sealant is pressurized to at least one hundred and fifty pounds per square inch for a pressurization period of at least sixty seconds. 
     
     
         8 . The method as recited in  claim 7 , wherein the tool assembly is rotated at a rotational velocity between approximately seventy-five revolutions per minute up to approximately one hundred and twenty-five revolutions per minute for at least three minutes. 
     
     
         9 . The method as recited in  claim 1 , wherein the sealant comprises a two-part epoxy and flowable ceramic material. 
     
     
         10 . A method comprising:
 receiving a tool assembly including a plurality of layers defining at least one part-cavity and plurality of cooling channels;   pouring sealant into the plurality of cooling channels;   pressurizing the sealant to a pressure for a pressurization period; and   applying a centrifugal force to the tool assembly to remove excess sealant from the tool assembly at a rotational velocity between approximately seventy-five revolutions per minute up to approximately one hundred and twenty-five revolutions per minute for at least three minutes, wherein the sealant extends between the plurality of layers.   
     
     
         11 . The method as recited in  claim 10 , further comprising:
 heating the tool assembly in an oven at approximately seventy degrees Celsius for approximately four hours.   
     
     
         12 . The method as recited in  claim 11 , further comprising:
 pouring the sealant into the tool assembly while the tool assembly is at or near seventy degrees Celsius.   
     
     
         13 . The method as recited in  claim 12 , wherein the sealant is pressurized to a pressure ranging from approximately sixty pounds per square inch to approximately one hundred pounds per square inch. 
     
     
         14 . The method as recited in  claim 13 , wherein the pressurization period comprises at least thirty seconds. 
     
     
         15 . The method as recited in  claim 13 , wherein the pressurization period comprises at least sixty seconds. 
     
     
         16 . The method as recited in  claim 12 , wherein the sealant is pressurized to at least one hundred and fifty pounds per square inch for a pressurization period of at least sixty seconds. 
     
     
         17 . The method as recited in  claim 10 , wherein the sealant comprises a two-part epoxy and flowable ceramic material. 
     
     
         18 . A tool assembly, comprising:
 an upper half defining at least one part cavity and a plurality of cooling channels; and   a lower half defining at least one part cavity and a plurality of cooling channels,   wherein each cooling channel of the plurality of cooling channels defines a surface that includes a pressurized and cured sealant extending between one or more layers and that coats the surface.   
     
     
         19 . The tool assembly of  claim 18 , wherein the sealant comprises a two-part high temperature cured epoxy. 
     
     
         20 . The tool assembly of  claim 18 , wherein the plurality of cooling channels are configured to connect to a temperature control system.